U.S. patent application number 10/891930 was filed with the patent office on 2006-01-19 for process for applying sleeve to pole and sleeved pole.
Invention is credited to John E. Irvine.
Application Number | 20060013978 10/891930 |
Document ID | / |
Family ID | 35597952 |
Filed Date | 2006-01-19 |
United States Patent
Application |
20060013978 |
Kind Code |
A1 |
Irvine; John E. |
January 19, 2006 |
Process for applying sleeve to pole and sleeved pole
Abstract
A plastic sleeve is applied to a pole of varying cross-sectional
area. A series of poles are advanced along their lengths through
the opening of an extruder die, plastic is extruded onto the pole
to form a cylindrical sleeve, and the rate of advancement of the
pole through the die is adjusted in accordance with the increasing
or decreasing diameter of the pole, so as to assure an even
application of the plastic about the pole. The ends of the plastic
are gathered while the plastic is still hot, forming a closure of
the plastic about the ends of the pole.
Inventors: |
Irvine; John E.; (Atlanta,
GA) |
Correspondence
Address: |
THOMAS, KAYDEN, HORSTEMEYER & RISLEY, LLP
100 GALLERIA PARKWAY, NW
STE 1750
ATLANTA
GA
30339-5948
US
|
Family ID: |
35597952 |
Appl. No.: |
10/891930 |
Filed: |
July 15, 2004 |
Current U.S.
Class: |
428/36.9 ;
264/161; 264/171.11; 264/237; 264/40.1; 264/510; 264/571 |
Current CPC
Class: |
B29C 2948/92619
20190201; Y10T 428/139 20150115; E02D 29/0266 20130101; B29C
2948/9258 20190201; B29C 2948/92333 20190201; B29C 2948/92085
20190201; B29C 2948/92123 20190201; B29C 48/92 20190201; B29C
2948/92828 20190201 |
Class at
Publication: |
428/036.9 ;
264/171.11; 264/040.1; 264/510; 264/571; 264/161; 264/237 |
International
Class: |
B29C 47/02 20060101
B29C047/02; B29C 47/92 20060101 B29C047/92; B32B 1/08 20060101
B32B001/08 |
Claims
1. A process of applying a plastic sleeve to a pole of varying
cross sectional area, comprising: advancing a plurality of
substantially rectilinear poles of varying cross sectional area
along their lengths in series along a processing path through the
opening of an extruder die, feeding a plastic material at
substantially a constant rate to the extruder die, continuously
applying the plastic material through the opening of the extruder
die about the exterior surface of each pole as each pole moves
through the extruder die and progressively surrounding the pole
with the plastic, detecting the thickness of a portion of the pole
at a position displaced upstream of the extruder die, and as the
detected portion of the pole enters the extruder die increasing the
rate of advancement of the pole in response to the detected portion
of the pole decreasing in thickness and decreasing the rate of
advancement of the pole in response to the detected portion of the
pole increasing in thickness.
2. The process of claim 1, and further including the step of
applying an area of reduced pressure between the plastic and the
pole to draw the plastic into contact with the pole.
3. The process of claim 1, and further including the step of
wrapping the plastic about the trailing end of the pole as the
trailing end of the pole moves away from the extruder die.
4. The process of claim 3, wherein the step of wrapping the plastic
about the trailing end of the pole comprises applying an area of
reduced pressure between the plastic and the trailing end of the
pole such that the plastic being applied by the extruder die to the
trailing end of the pole is induced to move about the trailing end
of the pole.
5. The process of claim 3, wherein the step of wrapping the plastic
about the trailing end of the pole comprises: as the trailing end
of a pole moves beyond the extruder die, gathering together the
plastic extending from the die to the trailing end of the pole.
6. The process of claim 3, wherein the step of wrapping the plastic
about the trailing end of the pole comprises mechanically gathering
the plastic extending from the trailing end of the pole and cutting
through the gathered plastic.
7. The process of claim 6, wherein the step of mechanically
gathering the plastic extending from the die to the trailing edge
of the pole and cutting through the gathered plastic comprises:
forming a closed end of the plastic for receiving the oncoming
leading end of the next pole in the series of poles, and cutting
the gathered plastic between the poles to separate the poles.
8. The process of claim 1, wherein the step of advancing the
plurality of poles comprises: advancing the poles at a rate
corresponding to the thickness of the poles to apply a uniform
thickness of plastic about the poles.
9. The process of claim 1, and further including the step of:
maintaining the longitudinal axis of the detected portion of the
pole substantially co-extensive with the longitudinal axis of the
extruder die as the detected portion of the pole passes through the
die.
10. The process of claim 7, wherein the step of maintaining the
longitudinal axis of the detected portion of the pole substantially
co-extensive with the longitudinal axis of the extruder die
comprises lifting the detected portion of the pole as it becomes
thinner and lowering the detected portion of the pole and it
becomes thicker.
11. A process of applying a plastic sleeve to a series of poles
each of varying cross sectional area, comprising: advancing a
plurality of substantially rectilinear poles along their lengths in
series along a processing path through the opening of an extruder
die, feeding a plastic material at substantially a constant rate to
the extruder die, continuously forming a sleeve of the plastic
material through the opening of the extruder die progressively
applying the sleeve of the plastic material about the exterior
surface of each pole as each pole moves through the extruder die,
detecting the thickness of a portion of the pole at a position
displaced upstream of the extruder die, and adjusting the rate of
advancement of each pole through the extruder die to correspond to
the thickness of the detected portion of the pole passing through
the extruder die to apply a uniform thickness of plastic in the
sleeve about the poles.
12. The process of claim 11, wherein the step of adjusting the rate
of advancement comprises increasing the rate of advancement of the
pole in response to a smaller thickness of the pole approaching the
extruder die, and reducing the rate of advancement in response to a
greater thickness of the pole approaching the extruder die.
13. The process of claim 11, and further comprising exhausting air
from between the sleeve of plastic material and the pole to draw
the sleeve into contact with the pole.
14. The process of claim 11, and further including wrapping the
ends of the pole with the plastic sleeve.
15. The process of claim 14, wherein the step of wrapping the ends
of the pole with the plastic comprises extending the extruded
sleeve beyond the end of the pole that has passed through the
extruder die and closing the extended portion of the sleeve about
the end of the pole without severing the sleeve, and continuing the
extrusion of the sleeve about the leading end of the oncoming pole,
severing the sleeve where the sleeve is closed between the poles to
form a closed end of the sleeve at the trailing edge of one pole
and a closed end of the sleeve at the leading end of the next
on-coming pole.
16. The process of claim 11, wherein the step of feeding plastic
material to the extruder die comprises feeding a plastic material
selected from the group consisting essentially of: polyvinyl
chloride, polypropylene, and polyethylene
17. The process of claim 16, and further including the step of
heating the plastic material before the plastic material is fed to
the extruder die, and progressively cooling the sleeve after the
sleeve has been applied to the pole.
18. The process of claim 17, wherein the step of heating the
plastic comprises heating the plastic to a temperature above about
350 degrees Fahrenheit and the step of cooling the sleeve comprises
applying a coolant to the sleeve until the temperature of the outer
surface of the plastic sleeve is lower than about 200 degrees
Fahrenheit.
19. The process of claim 11, wherein the step of advancing a series
of poles comprises moving the poles with an entrance conveyor
toward the extruder die and moving the poles with an exit conveyor
away from the extruder die, and cooling the sleeve applied to the
pole at a position between the extruder die and the exit
conveyor.
20. The process of claim 19, wherein the step of cooling the sleeve
applied to the pole comprises cooling the sleeve to a temperature
below about 200 degrees Fahrenheit before the sleeve contacts the
exit conveyor.
21. The process of claim 11, wherein the step of advancing a series
of poles comprises: the poles have one small end and one large end,
with the small end of each pole being smaller than its large end,
and the step of advancing the poles in series comprises advancing
each pole with the small end of each pole adjacent the small end of
the next adjacent pole.
22. A process of applying a plastic sleeve to a series of poles,
comprising: advancing a plurality of substantially rectilinear
poles along their lengths in series along a processing path through
the opening of an extruder die, feeding a plastic material at
substantially a constant rate to the extruder die, continuously
forming a sleeve of the plastic material through the opening of the
extruder die progressively applying the sleeve of the plastic
material about the exterior surface of each pole as each pole moves
through the extruder die, and adjusting the rate of advancement of
each pole through the extruder die to correspond to the thickness
of the detected portion of the pole passing through the extruder
die to apply a uniform thickness of plastic in the sleeve about the
poles.
23. The process of claim 22, and further comprising the step of
exhausting air from between the sleeve of plastic material and the
pole to draw the sleeve into contact with the pole.
24. The process of claim 23, and further including wrapping the
ends of the pole with the plastic sleeve.
25. The process of claim 24, wherein the step of wrapping the ends
of the pole with the plastic comprises extending the extruded
sleeve beyond the end of the pole that has passed through the
extruder die and closing the extended portion of the sleeve about
the end of the pole without severing the sleeve, and continuing the
extrusion of the sleeve about the leading end of the oncoming pole,
severing the sleeve where the sleeve is closed between the poles to
form a closed end of the sleeve at the trailing edge of one pole
and a closed end of the sleeve at the leading end of the next
on-coming pole.
26. The process of claim 22, wherein the step of feeding plastic
material to the extruder die comprises feeding a plastic material
selected from the group consisting essentially of: polyvinyl
chloride, polypropylene, and polyethylene
27. The process of claim 26, and further including the step of
heating the plastic material before the plastic material is fed to
the extruder die, and progressively cooling the sleeve after the
sleeve has been applied to the pole.
28. The process of claim 22', wherein the step of advancing a
series of poles comprises moving the poles with an entrance
conveyor toward the extruder die and moving the poles with an exit
conveyor away from the extruder die, and cooling the sleeve applied
to the pole at a position between the extruder die and the exit
conveyor.
29. The process of claim 22, wherein the step of advancing a series
of poles comprises: the poles have one small end and one large end,
with the small end of each pole being smaller than its large end,
and the step of advancing the poles in series comprises advancing
each pole with the small end of each pole adjacent the small end of
the next adjacent pole.
30. A pole for having a wooden core and a plastic sleeve wrapped
about the wooden core, said core being tapered along its length and
having a big end and a small end smaller in diameter than the big
end, a plastic sleeve wrapped about the pole, said plastic being
between 0.01 inch and 2.0 inches thick and being of substantially
uniform thickness along the length of the pole and characterized by
having been vacuum urged into intimate contact with the pole as
described in claim 13 and said plastic sleeve extending beyond the
ends of the pole and wrapped in a closed configuration about the
ends of the pole, such that the sleeve forms a water tight
enclosure about the core.
31. The pole of claim 30, wherein said pole is positioned upright
and has a lower end immersed in the earth and a portion adjacent
the lower end exposed to water or air.
32. A product formed by the process of claim 1.
33. A product formed by the process of claim 11.
34. A product formed by the process of claim 16.
35. A product formed by the process of claim 22.
Description
FIELD OF THE INVENTION
[0001] This invention concerns the application of a plastic sleeve
to a pole, a timber or other large rectilinear object for the
purpose of protecting it from deterioration from the environment
and other conditions. Also, the invention comprises a pole, timber,
or other elongated structural device that is surrounded by a
protective sleeve, for use as a structural support in harsh
environmental conditions.
BACKGROUND OF THE INVENTION
[0002] Poles, timbers and other elongated structures, herein after
referred to as poles, that are made out of wood or other materials
are commonly used as structural supports, and in many instances the
poles are subjected to impact and abrasion from external sources
and also subjected to severe atmospheric conditions that tend to
deteriorate the poles, requiring replacement, repair, etc. For
example, poles are used as piers that are partially embedded in the
earth and are impacted by water craft and other floating objects,
and are contacted by moving water, such as in rivers, lakes,
oceans, etc., and are subject to temperature extremes The wood of
the poles may also be subjected to deterioration from insect
infestation and chemical contact.
[0003] In order to protect wooden poles from conditions as
described above, chemicals are impregnated in or externally applied
to the surfaces of the poles, by painting, pressure application,
spraying, etc. The materials applied to the poles for preservative
purposes can include chromated copper arsenic known as CCA, ACQ,
and creosote. While these measures have extended the lives of
wooden poles, the application of the preservatives increases the
cost of the poles, and the poles still are directly exposed to
deterioration over extended times of use.
[0004] It is understood in the art that providing a protective
sleeve about a pole so that the sleeved pole can be successfully
used for extended periods in harsh conditions would be highly
desirable. However, the process of applying a protective sleeve to
a large pole and similar very large objects is difficult and
expensive, and the sleeve material is difficult to manage in the
application procedure.
[0005] One of the complicating factors in applying sleeves to poles
is that poles typically are made from timber, trees harvested from
forests, and the natural shape of a tree is tapered, larger at the
bottom and smaller at the top. Moreover, some trees are not exactly
rectilinear and may have unexpected fat and thin areas about its
length and knots where limbs have been removed. These shape
characteristics of a typical tree complicate the process of
applying a sleeve to the pole.
[0006] This invention is directed to an improved process for
applying a protective sleeve to a pole formed from a tree and to
other similarly shaped items, and to the product formed by the
process.
SUMMARY OF THE INVENTION
[0007] Briefly described, the present invention comprises a process
of applying a plastic sleeve to a pole of varying cross-sectional
area. The process includes the steps of advancing a plurality of
the substantially rectilinear poles of varying cross-sectional area
along their lengths in series along a processing path. The poles
are pushed through an opening of an extruder die. Plastic material
is heated and fed at a substantially constant rate to the extruder
die. The plastic is continuously applied through the opening of the
extruder die about the exterior surface of each pole in series, as
each pole moves through the extruder die, with the plastic
progressively surrounding the pole.
[0008] In order to apply the plastic material in a substantially
uniform thickness to a pole having a varying diameter, more plastic
is required at the thicker portions of the pole than at the thinner
portions of the pole. In order to achieve the uniform thickness
application of the plastic, the thickness of each pole is
progressively measured so that each portion of each pole is
measured at a position displaced upstream of the extruder die. As
the detected portion of the pole enters the extruder die, the rate
of feeding the plastic material does not change, but the rate of
advancement of the pole is adjusted in accordance with a change in
the detected thickness of the pole. The rate of advancement of each
pole is adjusted to correspond to the change in thickness of the
detected portion of the pole passing through the extruder die so as
to apply a uniform thickness of plastic in the sleeve about the
poles.
[0009] More specifically, as a detected portion of a pole enters
the extruder die, the rate of advancement of the pole is increased
in response to the detected portion of the pole decreasing in
thickness, and the rate of advancement of the pole is decreased in
response to the detected portion of the pole increasing in
thickness.
[0010] Another feature of the invention is the application of a
negative air pressure between the plastic sleeve being applied to
the pole and the pole itself, so as to draw the plastic sleeve into
intimate contact with the pole. This assures that the plastic
material of the sleeve is supported by the pole, the plastic tends
to cling to the pole, and the thickness of the plastic is
maintained substantially uniformly about the circumference and
along the length of the pole.
[0011] Another preferred embodiment of the invention is that the
poles are advanced in a continuing process, end to end, so that the
extruding process is also continuously maintained with the sleeve
of plastic extending from pole to pole. The segment of the sleeve
extending between adjacent poles is severed, and the excess sleeve
material is wrapped about the ends of the poles, thereby forming
the sleeve into an envelope that envelopes the entire pole. The
step of wrapping the plastic about the trailing and leading ends of
the poles includes the application of an area of reduced pressure
between the plastic and the trailing and leading ends of the
adjacent poles such that the plastic being applied by the extruder
die to the ends of the poles is induced to move about the ends of
the poles.
[0012] Also, the step of wrapping the plastic about the ends of the
pole can comprise a mechanical gathering of the plastic extending
from adjacent poles.
[0013] Another aspect of the invention is the step of maintaining
the longitudinal axis of the detected portion of the pole
substantially coextensive with the longitudinal axis of the
extruder die as the detected portion of the pole passes through the
die.
[0014] The plastic material extruded into the sleeve about the pole
may comprise polyvinyl chloride, polypropylene, and polyethylene,
as well as several copolymers. The plastic material usually will be
selected in anticipation of the end use of the pole.
[0015] A general concept is to capitalize on the beneficial
properties of wood, such as strength, low cost, availability, and
ease of use, and to eliminate the negative attributes by
incorporating a plastic sleeve on the exterior of the wood. The
plastic sleeve serves several purposes, including: it provides
protection for the wood from the environment, creating a much
longer life cycle: it protects people and the environment from the
wood and any chemical preservatives in the wood; and the plastic
coating provides an esthetic purpose in that it can be produced in
various colors and it hides any knots and checks or other
imperfections in the wood.
[0016] The plastic sleeve protects the wood from the environment in
several ways. It protects from the ultraviolet light from the sun
that can break down the fibers in the wood and cause a reduction in
its structural strength. The sleeve reduces the amount of available
oxygen at the surface of the wood and thereby reduces the ability
of any insects or parasites to survive and destroy the wood.
[0017] Also, in a marine environment where the sleeved pole
functions as a pile, the plastic sleeve serves as a barrier to
marine borers that eat the wood. The sleeve has a smoother surface
than the wood of the pole so the sleeve also reduces the potential
damage from pile up-lift caused by ice in cold weather regions
because the ice is not as likely to adhere to the plastic sleeve as
well as it would adhere to the surface of the wood pole.
[0018] Also, the smooth exterior surface of the outer sleeve of the
invention eliminates exposure to splinters in the surface of the
wood. The sleeve also minimizes the possible transfer of chemical
preservatives in the wood into the environment or into people's
hands and skin. The amount of chemical preservatives required in
certain applications of the poles may be reduced due to the
additional protection provided by the plastic sleeve.
[0019] There are numerous applications for the work product, such
as playground equipment, railroad ties, seawalls, retaining walls,
pilings and other applications where longevity of the wood is a
concern, safety of people or animals contacting the wood is a
concern, or protection of the environment is a concern.
[0020] Thus, it is an object of this invention to provide an
improved process for applying a plastic sleeve to a pole that may
have a varying cross-sectional area along its length.
[0021] Another object of this invention is to provide a process for
applying a plastic sleeve about a pole so that the plastic is in
intimate contact with the surface of the pole and the thickness of
the plastic sleeve is substantially uniform along the length of the
pole.
[0022] Another object of this invention is to provide an improved
sleeve-covered pole having-a sleeve that protects the pole-from
harsh conditions occurring in the atmosphere and the surroundings
of the pole.
[0023] Another object of this invention is to provide an improved
process for applying a plastic sleeve to a large pole that is
inexpensive, expedient and reliable.
[0024] Other objects, features, and advantages of the present
invention will become apparent upon reading the following
specification, when taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a partial perspective view of the end of a pole
having a plastic sleeve applied thereto, with a portion of the
sleeve removed to expose the pole.
[0026] FIG. 2 is a schematic diagram of the process of applying
plastic sleeve material about a series of poles moving along a
processing path.
[0027] FIG. 3 is another schematic, similar to FIG. 2, but showing
more details of the process.
DETAILED DESCRIPTION
[0028] Referring now in more detail to the drawings in which like
numerals indicate like parts throughout the several views, FIG. 1
illustrates an end portion of a sleeved pole 10 that includes an
end portion of a wooden pole 12, and a cylindrical plastic sleeve
surrounding the pole. The sleeve extends beyond the ends of the
pole and is gathered about at its ends to envelope the pole and
form a water tight barrier about the wooden pole, as shown at the
gathered end portion 16. The wooden pole 12 typically is tapered
along its length, usually having a big end and a small end, with
the small end smaller in diameter than the big end. The pole also
may have irregular shapes along its length.
[0029] The sleeve wrapped about the pole is substantially uniform
in thickness, usually being between 0.01 inch and 2.0 inches in
thickness for most uses; however thinner and thicker sleeves can be
produced with the process. The sleeve is characterized by having
been vacuum urged into intimate contact with the wooden pole. The
wrapping of the plastic sleeve about the ends of the poles is
performed when the end of one pole exits the extruder and a
following pole closely follows, so that the hot plastic of the
overhanging sleeve, when gathered together between the adjacent
ends of the poles, tends to cling to itself and to the end of the
pole, usually sealing the end of the pole from the atmosphere.
Thus, the sleeve 14 of the sleeved pole 10 forms a substantially
water-tight exterior envelope,-shielding the pole 12 from the
environment.
[0030] As illustrated in FIG. 2, the process of applying the sleeve
to a pole starts with the provision of standard timbers or pilings
20 being loaded in parallel relationship onto an accumulator 22
that holds a sufficient number of the timbers so that they can be
continually fed into the entry of the processing path. The
processing path is indicated by the arrows 18. There is no limit to
the sizes of the poles that can be handled by the system, except
that the components of the system must be able to handle the weight
and physical size of the poles. Preferably, the poles are placed in
longitudinal alignment with one another along the processing path,
with the adjacent ends of the poles being spaced apart about two to
three feet.
[0031] The poles move in sequence from the accumulator feeder 22
into a entrance or pusher conveyor 24, through a speed and diameter
sensor 26, through vacuum box 28 and extruder die 30 which receives
molten plastic from extruder 32. As each pole, such as pole 20A,
moves through the extruder die 30, the plastic is extruded in a
circular configuration toward longitudinal axis of the pole, and
the progress of the pole through the die tends to form the circular
plastic into an elongated sleeve that extends about the pole.
[0032] The pole with its hot sleeve applied to it progressively
passes through a cooler 34 which cools the surface of the plastic,
and the pole is then received on an exit conveyor or puller 36.
[0033] Once the now sleeved pole moves beyond the cooler 34, the
pole can be transferred to a storage platform 38 where it continues
to cool and where it is available for movement, usually by a
forklift, to another destination where it is to wait for shipment
to a construction site.
[0034] The rate of advancement of the poles through the extruder is
controlled by the speed controller 40. The speed controller
communicates with the speed and diameter sensor 26 and adjusts the
speed of the entrance conveyor 24 and the exit conveyor 36, with
these conveyors usually operating at identical rates of speed.
[0035] FIG. 3 shows more details of some aspects of the process
described above. The pusher or entrance conveyor 24 includes upper
and lower belt conveyors 42 and 43 of rugged construction that are
capable of handling the large size and weight of the timbers or
pilings 20. The upper and lower belt conveyors are movable and
adjustable during the processing of the poles so as to make sure
that the longitudinal axis 44 of each pole is aligned with the
extruder die 30 and the other elements of the processing path.
Also, the upper and lower belt conveyors 42 and 43 are movable
toward and away from each other so as to positively grip the poles
and restrain the poles from undesired lateral movements.
[0036] As the poles are advanced by the conveyors 42 and 43 into
the extruder die 30, they first pass through the speed and diameter
sensor 26. FIG. 3 shows the speed and diameter sensor 26 as being a
mechanical device, such as a wheel applied to the surface of the
pole so that the wheel rotates in response to the movement of the
pole. The rotational movement of the wheel is detected and is fed
to the speed controller 40, and that information is then used to
adjust the speeds of the entrance conveyor 24 and exit conveyor 36.
The same or similar device is used to detect the thickness of the
pole. This measurement is used to adjust the heights of the upper
and lower entrance conveyors 42 and 43. While the speed controller
40 has been indicated as being a mechanical device, various optical
devices are available for making speed and height detections and
can be used in a similar manner to control the conveyors.
[0037] The speed and diameter sensors 26 are positioned at a known
distance from extruder die 30 so that the portions of the pole
measured by the speed and diameter sensors 26 are recorded and when
each detected portion approaches the extruder die 30, the rate of
advancement of the pole 20A is adjusted as may be necessary to
accommodate for the pole decreasing in thickness or increasing in
thickness, as described above.
[0038] The extruder die 30 is a circular die, having an opening 50
and the extruder 32 supplies molten plastic usually at a constant
rate to the extruder die. The plastic is supplied by the die in a
circular arrangement that is directed toward the cylindrical shape
of the pole and as the pole is pushed through the die, it carries
the plastic with it so that the plastic forms a sleeve about the
cylindrical surface of the pole.
[0039] As the pole approaches the extruder 30, it passes through
the vacuum box 28. the vacuum box includes a plurality of flexible
seals 52 that seal the inside of the vacuum box about the pole. A
blower 54 draws air from within the vacuum box to the outside so
that the pressure of the atmosphere inside the vacuum box 28 is
reduced. This tends to cause the pressure of the atmospheric air
outside the vacuum box to be applied as indicated by arrow 56 into
the exit of the vacuum box 28, thereby urging the plastic extruded
from the extruder die 30 to be applied intimately with the surface
of the portion of the pole moving through and just beyond the
extruder die.
[0040] When the pole, such as pole 20B of FIG. 3, moves beyond the
extruder 30, the pole progressively passes through the cooler 34.
The cooler 34 applies chilled air to the exterior of the plastic
sleeve that is now applied to the pole. A heat exchanger 60 chills
the atmospheric air, blower 62 draws the air through the heat
exchanger and delivers the air to the cooler 34 so that the flow of
chilled air within the cooler 34 is applied aggressively to the hot
plastic of the sleeve.
[0041] While chilled air is a good coolant, other fluids can be
used, such as nitrogen gas and liquids such as sprayed water.
[0042] The extruder 32 heats the plastic so that when the plastic
is applied to the pole it is in a molten state. The temperature of
the plastic as it is extruded will vary with the kind of plastic,
but the typical temperature would be about 350 degrees F. for
polyvinyl chloride to assure that it is pliable enough to flow
through the extruder die and to collapse on the surface of the pole
and respond to the reduced pressure of the atmosphere within the
vacuum box-to achieve the intimate contact with the surface of the
pole. However, it is also desirable to have the sleeve at a lower
temperature when the sleeved pole 20B reaches the exit or pull
conveyor 36 so that the plastic sleeve will not cling to or become
excessively deformed by its contact with the exit conveyor. This
lower temperature should be less than about 200 Degrees F. for
polyvinyl chloride. Other high and low temperatures would be
identified for other plastic materials.
[0043] As the series of poles progress beyond the extruder die 30,
it is desirable to form the gathered portions of the sleeves about
the ends of the poles. This should be done while the plastic
material is still hot so that it clings to itself at the ends of
the poles and provides a watertight seal about the poles. As shown
in FIG. 3, a pair of oppositely moving gathering plates 60
reciprocate toward and away from each other, so that when the
plates are spaced apart they form a passage therebetween as the
body of each pole moves along the processing path. Once the
trailing end 62 of a pole passes the position of the gathering
plates 60 and before the leading end 64 reaches the gathering
plates, the gathering plates are moved together between the poles,
thereby forming the folded-in portions 16 (FIG. 1) at the adjacent
ends of the poles. If desired, the gathering plates 60 can have a
scissors movement and can have edges that are shaped for inducing
the gathering and sealing of the plastic to itself, such as
V-shapes. The reduced pressure created by the vacuum box 28 tends
to collapse the span of the sleeve extending between the adjacent
ends of the poles so that when the gathering plates urge the sleeve
closed the air in the sleeve is evacuated, tending to cause the
sleeve to make more intimate contact with the adjacent ends of the
poles.
[0044] As previously stated, the poles, such as poles 20A and 20B,
typically will be tapered along their lengths, with each pole
having a big end and a small end. Usually, the poles will be loaded
into the apparatus so that the big end of each pole is located
adjacent the big end of the next adjacent pole, and with the small
end of each pole located adjacent the small end of the next
adjacent pole. With this loading process, the system usually will
not have to make a radical adjustment of the rate of advancement of
the poles along the processing path.
[0045] It is anticipated that some poles will have large ends that
are too larger for passing through the die of the extruder or have
protruding splinters or protrusions from the removal of limbs that
might not pass through the die. The large portions of the pole are
trimmed to a size to pass through the die. The trimming of the
large portions of the poles can be done by conventional equipment
prior to loading the poles on the entrance conveyor, or the trimmer
can be used at the entrance conveyor.
[0046] Because the extruder 32 applies a constant volume of plastic
to the extruder die 30, and because the diameter of the typical
pole at the extruder die 30 is likely to progressively change, the
rate of advancement of the pole may be adjusted to assure that a
substantially constant thickness of plastic is applied to the pole
by the extruder die, resulting in a substantially constant
thickness of the sleeve formed about the pole.
[0047] Also, it may be desirable to raise and lower the conveyors
24 and 36 to accommodate radially different sized poles to handle
thicker or thinner poles, or to raise or lower the conveyors during
the processing of a single pole to accommodate for its thinner or
thicker portions. In the alternative, it may be desired to adjust
the position of the extruder die 30 in response to the position of
the portion of the pole passing through it. In either instance, it
is desirable to have the longitudinal axis of the pole 44 be
coextensive with the components of the system, particularly with
respect to the extruder die 30.
[0048] This process allows for the use of any type of wood and any
type of preservative treatment of the wood, or no preservative at
all. It has been found that southern yellow pine pressure treated
poles with 0.8 to 2.5 pounds per cubic foot of chromated copper
arsenic (CCA) can be effectively used in the system. Other poles
and elongated structures can use this application process, to cover
the poles with plastic, such as fiberglass, reinforced plastic,
wood flour composites, steel, aluminum, etc. A wide range of
plastics also can be used to sleeve the timber, depending on the
end use of the product. Certain plastics have better resistance to
certain chemicals, for example, and other may have better
weatherability. The end use will dictate the performance
requirements and, therefore, the properties of the plastic to be
utilized. Successful plastics utilized today include
polyvinylchloride, polypropylene, polyethylene, as well as several
copolymers.
[0049] The plastic sleeve is intimately applied to the surface of
the core product, such that it tends to cling on its own accord to
the product, and it takes on a shape of the core product, such as
conforming to the exposed grain of the wooden pole.
[0050] The reduction in pressure of the atmosphere inside the
vacuum box may be adjustable so as to optimize the rate of movement
of the plastic against the surface of the pole. The larger the
distance between the plastic and the pole, the greater the need for
more pressure differential. For example, a pressure differential of
as low as two pounds per square inch can induce the intimate
contact of the plastic to the portion of the pole passing through
the extruder die if the distance of movement of the plastic is less
than about one inch. However, as the distance of movement of the
plastic into contact with the pole increases, up to as much as 15
to 20 pounds per square inch of pressure differential may be
required. In addition, the viscosity of the plastic, depending on
the type of plastic and the temperature of the plastic, has some
effect on the pressure differential required in the process.
[0051] While the process has been described as applying to poles
having varying cross sectional area along their lengths, the
process can be applied to poles that have long lengths of constant
cross sectional area, to timbers or other objects that are of
substantially constant cross sectional area along their entire
lengths, without the necessity of varying the rate of advancement
of the object.
[0052] Although a preferred embodiment of the invention has been
disclosed in detail herein, it will be obvious to those skilled in
the art that variations and modifications of the disclosed
embodiment can be made without departing from the spirit and scope
of the invention as set forth in the following claims.
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